Catenary Troughing Idler With Independent Rollers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catenary idlers are inadequate for handling extremely high impact loads in conveying systems, as they often bind due to friction, create weak spots, or induce twist in the conveyor belt, especially when dealing with large aggregates dropped from height.
Innovation Solution
A catenary idler design featuring a braided wire cable with a bearing layer and rollers that have low friction, sliding surfaces, and independent rotation, supported by compression springs and thrust bearings, allowing for improved impact absorption and reduced friction along the conveyor belt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional catenary idlers with rigid connections are used, then structural stability is maintained, but they bind due to friction and cannot handle high impact loads
Solution Approach 1:
The catenary idler is divided into multiple independent roller segments that can rotate independently on the cable. Each roller is separated by spacing elements, allowing individual rotation without binding the entire structure. This segmentation enables the idler to accommodate high impact loads while maintaining low friction through independent roller rotation.
Solution Approach 2:
The patent changes the friction parameter by using low-friction bearing surfaces between the rollers and the cable. The bearing surfaces are designed with specific geometric parameters (concave cylindrical shape) and material properties that reduce the coefficient of friction, allowing rollers to rotate freely even under high impact conditions.
2Shape
If rollers are connected in series with pivot connections, then the catenary shape is formed, but the connections contact at high troughing angles and bind
Solution Approach 1:
Instead of using continuous pivot connections between rollers, the patent segments the structure by placing individual rollers on a flexible cable with spacing elements between them. This eliminates the pivot connection binding issue while maintaining the catenary shape through the cable's flexibility and the rollers' independent positioning.
Solution Approach 2:
The cable acts as an intermediary element between the rollers, replacing the direct pivot connections. The cable transmits the catenary shape formation function while allowing each roller to rotate independently without friction-induced binding that occurs in direct pivot connections.
3Shape
If the entire cable rotates to form the catenary shape, then the shape is achieved, but rollers may slide instead of roll and twist is induced
Solution Approach 1:
The patent segments the rotation function by allowing only the individual rollers to rotate on the cable, while the cable itself remains relatively stationary in terms of rotation. This prevents the twist induction that occurs when the entire cable rotates, while still achieving the catenary shape through the spaced rollers' independent rotation and positioning.
Solution Approach 2:
Instead of having the cable rotate to form the catenary shape (as in conventional designs), the patent inverts the approach by having the rollers rotate independently on a stationary or minimally rotating cable. The catenary shape is achieved through the spatial arrangement of the rotated rollers rather than through cable rotation, eliminating twist and sliding issues.
4Strength
If rigid impact beds are used in the loading zone, then high impact loads are handled, but the solution is confined to limited zones and does not span the entire conveyor belt
Solution Approach 1:
The catenary idler design with independent rotating rollers serves multiple functions: it provides impact absorption capability throughout its entire length, maintains low friction for belt movement, and can be deployed along the entire conveyor belt span. This universal design replaces the need for separate rigid impact beds confined to specific zones, allowing the entire conveyor belt length to function as a loading zone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances impact absorption and reduces friction and twist in the conveyor belt, enabling the use of the entire conveyor belt length as a loading zone, even under high impact conditions, and allows for independent rotation of rollers to manage varying belt speeds without inducing twist.
Implementation Method 1
The idler may include compression springs at its two ends that support the cable
Implementation Method 2
The cable may be rotatably supported at its first end and its second end
Data Source
AI summary
A catenary idler comprises a cable, a plurality of bearing surfaces disposed along a length of the cable, and a plurality of rollers disposed over the plurality of bearing surfaces. The plurality of bearing surfaces are fixed to the cable. The plurality of bearing surfaces may be a plurality of clamps. The plurality of rollers are rotatably supported upon the plurality of bearing surfaces. The cable may be rotatably supported at its ends. The catenary idler may include a first compression spring at a first end of the cable and a second compression spring at a second end of the cable. The rollers may be formed of an oil filled nylon. A conveyor belt impact bed includes a frame, a plurality of catenary idlers supported upon the frame, and a conveyor belt supported upon the plurality of catenary idlers.